Machine and method for erecting a carton and integral cover on one operation



Feb- 10, 1959 w.-.1. FAHRENKRUG 2,872,855

MACHINE AND METHOD EOE ERECTTNG A CARTON AND INTEGRAL oovEE oN oNE OPERATION Filed Aug. 10, 1953 6 Sheets-Sheet 1 W/LLA'eo J. mwen/Keus- Feb. 10, 1959 FAHRENKRUG MACHINE AND METHOD FOR ERECTING A CARTON 6 Sheets-Sheet 2 AND INTEGRAL COVER 0N ONE OPERATION Filed Aug. 10. 1955 f... .w R E V e ill w N H r 1 n F J. n QS m v. l WM B O @s 00M Ql f 4444 i f 1:12..:.a000.:..:..muifuww.I Qen '0% Q .VNI mw bw mm e m QWNN Feb. 10, 1959 w. J. FAHRENKRUG MACHINE AND MET 2,872,855 HOD FOR ERECTING A CARTON AND INTEGRAL COVER 0N ONE OPERATION Filed Aug. 10. 1953 6 Sheets-Shree?l I5 Lamy/JJM A r faena-V5 Feb. l0, 1959 w. J. FAHRENKRUG 2,872,855

MACHINE AND METHOD FOR ERECTING A CARTON AND INTEGRAL COVER oN ONE OPERATION Filed Aug. 1o. 195s e sheets-sheet 4 I IN V EN TOR.

Feb. l0, 1959 w..1. FAHRENKRUG MACHINE AND METHOD FOR ERECTING A CARTON E.' OPERATION AND INTEGRAL COVER ON ON 6 Sheets-Sheet 5 Filed Aug. 10, 1953 www Feb. l0, 1959 w. J. FAHRENKRUG MACHINE AND METHOD FOR ERECTING A CARTON AND INTEGRAL COVER oN ONE OPERATION 6 Sheets-Sheet 6 Filed Aug. 10. 1955 G 5 d Y E M mw me L, mm M tutti MACHINE AND ME'HGD FOR ERE'C'IINGv A vCARTON ANDINTEGRAL CGVER N ONE OPERATION Willard J. Fahrenkrug, Peslitigo, Wis., assigner to Badger Paper Mills, Inc., Peshtigo, Wis., a corporation of Wisconsin Application August 10, 1953, Serial No. 373,268 14 clams. (ci. 93-51) This invention relates to a machine and method for erecting a carton and integral cover in one operation.

Starting with a single blank integrally providing component parts of the carton and its cover, the machine forms in each operation a tray-like carton and a cover which has separately glued iront and end walls and is in hinged connection with the tray to be foldable to and from closed position thereupon.

The erecting operation involves the action of a first ram to push the tray-forming portion of .theY blanl; through an apertured die which is so notched as to provide work-engaging portions that fold the parts into mutual engagement in proper sequence. There are cooperating plungers which subject lapping portions of the blank to pressure pending the setting of the glue with which they have been coated.

These operations are performed during continued downward movement of the tray portions of the blank in the course of which a retractable element `of the die is moved out of the way to permit the passage of the cover and to provide supplemental support. A. separate ram then comes in to engage the cover walls while these, in turn, are folded up and set, the downward movement of the carton continuing until a completed carton is discharged beneath the die.

In the drawings:

Fig. 1 is a view in perspective showing that portion of the carton erecting machine with which the present invention is concerned.

Fig. 2 `is a View of the machine in longitudinalsection.

Fig. 3 is a view oi the machine in end elevation partially broken away on the section indicated. on 3--3 in Fig. 2.

Fig. 4 is a view in perspective showing an open `but otherwise complete `carton embodying the invention.

Fig. 5 is a view on an enlarged .scale showing the carton in transverse section.

Figv 6 is a view on a reduced ,scale ,showing the blank from Vwhich the carton Yis formed.

Fig. 7 is a plan View fragmentarily illustrating Vthe carton blank in position upon the erecting die, ythe ram being shown in Vhorizontal section.

Fig. 8 is a fragmentary plan View showing the commencement of erection operation .as the ram (shown in section) descends.

Fig. 9 is a view in longitudinal section of the part shown in Fig. 8.

Fig. 10 is a View .in perspective showing the carton blank having its components partially folded to the Vpositions indicated in Figs. 8 and 9.

Fig. 11 is a view similar to Fig. 8 showing a subsequent sta-ge of the blank erecting operation.

Fig. '12 is a View .similar to Fig. 9 showing-.inlougitudinal section theposition of the parts illustrated in plan in Fig. 11.

13 is a fragmentary view in perspective `.showing the carton in the stage indicated "niFi'gs A11 and 12.

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Fig. 14 is a view similar to Figs. 8 and 11 showing a succeeding stage in the erection of the carton.

Fig. 15 is a View similar to Figs. 9 and 12 showing the apparatus in longitudinal section as it appears at the stage of Fig. 14.

Fig. 16 is a fragmentary view in perspective showing the carton erected to the stage shown in Figs. 14 and 15.

Fig. 17 is a View similar to Figs. 8, 11 and 14 showing the final stage in the erection of the carton and its cover.

Fig. 18 is a. View corresponding to Figs. 9, 12 and 15 showing in dotted section the parts illustrated in Fig. 17.

Fig. 19 is a fragmentary detail view in perspective showing the carton erected to the form illustrated in Figs. 17 and 18.

Fig. 20 is a fragmentary detail view in longitudinal section showing how the carton is held during the retraction of the punch or ram.

It Will be understood that specific details of the machine and the operations employed are merely illustrative.

The carton which it is desired to produce is clearly illustrated in Figs. 4, 5 and 6. There is a tray portion generically designated at 21 which has front and rear walls 22 and 23 and end walls 24 and 25, all of such walls being integral with wall Z6. The front wall has end tabs 27 and 28 and the rear wall has similar tabs 29 and 30. These are folded inwardly into substantially abutting relation within the end walls 24 and 25. as clearly shown in Fig. 4 and Fig. 5 and the end walls are secured thereto to complete the tray assembly.

In hinged. connection with the rear wall Z3 upon a scored fold line 32 is a cover panel 33 which has a front wall 34 with a separate panel 3S olded inwardly upon itself at 36 to provide a reenforced edge across which the operator may pull paper from the roll within the carton in order to, sever individual sheets. Bracing the wall 34 so that it may withstand this pulling operation, are the tabs 37 and 3S adhesively connected with end walls 39 and 4t) respectively.

The cover as above described is generically designated by reference character 41.

rlhe blank, scored as indicated by dotted lines in Fig. 6, is advanced along feed table 42 of the erecting machine as shown at 43 in Fig. 2. For advancing the blank, a conveyor chain 4d with lugs may conveniently `be used. in the course of its advance, the blank passes beneath a pair of glue rolls .46 with peripheral pads 47 which receive glue from a transfer roll 48 which operates in a glue vat 49. The positions at which the pads 47 are carried on each roll 46 is such thateach pad on each Wheel (Fig. 1 and Fig. 2,).y will .apply adhesive to selected portions rof the blank which, `tor the purposes of the present invention, `comprise the end walls 2e and 25 of the tray Vandthe end` walls 3,9 .of the. cover, the adhesive being represented by the ,stippling of vwalls 25 andV 39 in Figs. 7, 8 and 11.

After `the conveyor chain 44 releases the successive blanks, these are frictionally advanced by feedV rolls e9. and 5t) (Fig. 2) into engagement with stop blocks 51 at the end of forming die 52 which constitutes an extension of the table 42. The .die is bifurcated to provide forwardly 4projecting Aarms 54 and 55 asbest illustrated in Fig. 7, these arms being laterally spaced .at a distance which is substantially .equal .to the length ofthe bottom and front and rear wall panels of .the tray and the top panel 33 of the cover. Those edges of the arms 54and 55 which are opposite the positions at which panels 22 and 23 `come to rest are continuous and unnotched. There are, however, ,notches at 56 and 57 underlying/the baseporfion of the .end wall panels 24 and 2S, the outer ends Yof the .respect-ive .lend wall panels beingsupported Vby the die.

Spaced longitudinally of the respective arms 54 and 55 of the die from notches 56, 57 are additional notches 58 and 59. These notches are not squarecut but have oblique outer margins 60 and 61 respectively, the angle of inclination being such that support is provided for tabs 29 and 30 of the blank, said support being indicated for tab 29 in Fig. 7. Further support for these Vtabs is provided by tongue portions 62 and 63 of the die which separate notches 56 and 58 `of arm 54 and notches 57 and 59 of arm 55. The tongues 62 and 63 desirably have straight edges adjacent notches 58 and 59, but extend curvilnearly from their extremities adjacent notches 56 and 57. It will hereinafter be explained that the arrangement is such as to promote the immediate folding of the flaps 29 and 3G, ahead of end walls 25, 26, during the initial erection of the carton tray, while permitting the delayed folding of the cover Vend walls 39 and e@ when these latter register with notches 58 and 59.

As the blank reaches the position on the die which is shown in Fig. 7, the bottom panel 26 Vof the tray is ecn- 'tered `beneath a punch or forming block ram 65 of substantially identical area in plan. This is supported, as best shown in Fig. 2, upon the rearwardly projecting arm 66 of a vertically reciprocable slide at 67 for which guidcways are provided at 68 in the spaced columns 69 and 76. In the initial erecting operation, the punch block 65 descends as shown in Figs. 8 and 9 to engage the bottom panel 26 and force it downwardly through the die 52. The first elect of the downward displacement of the blank with respect to the arms 54 and 55 of die 52 is to cause a relative upward movement of the several tabs 27, 28, 29 and 30. These, being supported on rigid portions of arms 54 and 55, swing immediately toward positions at right angles to the front and rear Wall panels 22 and 23 to which such tabs are integrally connected.

Wall panels 22 and 23 are now swung upwardly as shown in Fig. 9 and Fig. l0 by engagement respectively with the transverse folding bar 71, in the path of panel 22 and the edge 72 of a retractable formingA element 73 which lies in the path of panel 23. The end wall panels 24 and 25 do not swing upwardly as rapidly as do the end wall flaps above referred to, this being due to the notches 56 and 57 beneath the end wall panels, such notches partially relieving the end wall panels of upward folding pressure. As the result of this initial folding operation, the described portions of the blank move to the positions shown in Fig. 10.

t Figs. 1l, l2 and 13 show the relative positions of the Iblank and the punch and die at a subsequent stage of the continued downward movement. The punch continues to push the tray-forming portions of the blank through the constricted space between the bar 71 and the edge 72 of the retractable die element 73 to such an extent that the panel 22 and the rear wall panel 23 of the blank are now drawn snugly against the front and rear faces of punch block 65. The score line at 32 constituting the hinge between the tray and cover now registers with the forward margin 72 of die element 73. The flaps 27, 28, 29 and 30 have all been folded in against the end surfaces of the block 65. The end walls 24 and 25 have beenformed upwardly toward engagement with the said flaps 27, 28, 29 and 30. The upward fold ing of the end walls.24 and 25 is delayed in consequence of their registry with notched portions of the die arms 54 and 55, whereby the aps are allowed to move into place in advance of the end walls. The end walls are finally erected when continued downward movement of the forming block and blank forces the end walls between the plungers 75 and 76, which hold the end walls tightly against the aps 27, 28, 29, 30, previously turned in upon the block.

f As the blank is erected to the extent indicated in Figs. r11, 12 and 13, the downward movement of panel 23 and the ap 39 has moved, as best shown in Fig. ll, to a position in which its trailing margin now registers with the notch 53 in the die arm 54, it being understood that the other end of the box ap 40 is in similar registry with notch 59. However, the downward movement of the tray-forming portions of the blank has pulled the margins of the flaps 39 and 40 beneath the respective fingers 62 and 63 as shown in Fig. 1l and Fig. l2. Meantime, an auxiliary cover-forming punch `block has descended from the retracted position in which it is shown in Fig. 1 and Fig. 9 to the position shown in Fig. l2 in which it is in substantial engagement with cover panel 33 and has slightly depressed the trailing edge thereof, thereby pushing tab 37 across the die arm 54 to cause an initial relative folding of tab 37, it being understood that corresponding ta'b 38 at the other end of the box has similarly been folded upwardly.

The auxiliary punch block 80 is carried on arms 81 and 82 which are mounted on a rock shaft 33 for which bearings are provided on the arms 66, which support punch yblock 65 from slide 67. Arocker arm 84 connected with rock shaft 83 is biased `by tension spring 85 anchored to the slide 67 whereby the auxiliary punch block 81') is normally held in an elevated position. However, as the slide descends, the arms 87, likewise connected with rock shaft 83, engage the resilient stops 88 (Fig. l) whereby the rock shaft is oscillated against the `bias of 4spring 85 to lower the auxiliary block 80 with respect to punch block 65 for a cover erecting operation, which has been initiated in the position of the parts shown in Fig. l2 and Fig. 13.

As the slide continues downwardly, thc auxiliary punch block 80 moves into lateral abutment with the punch block 65 and the two descend together as shown in Figs. 14, 15, 17, and 18. The retractable die element 73 first moves out of the way as shown in Fig. l5 to allow the descent lof the cover panel 33. The wall portion 34 of the blank is turned upwardly as it is forced past the stationary die element 90, its turned bead 35 abutting the rear face of the block 80. The cover end walls 39 and 40 are forced past the somewhat retracted glue-setting plungers 92, 93 and are thereby relatively turned upwardly outside of the previously inturned tabs 37, 3S as shown in Figs. 14 and 16.

To complete the box and cover, the glue-setting plungers 75 and 76 move in to press the glue-coated end walls 24 and 25 against the flaps 29 and 27 at one end of the box and 30 and 28 at the other. Simultaneously, the glue-setting plungers 92 and 93 move in to set the gluecoated end walls 39 and 40 of the cover against the tabs 37 and 38 at the respective ends of the front wall panel 34. Momentary pressure suices to make the adhesive the downward movement of the carton in the course of v the erecting operation above described. They are so close to the plungers or rams 75 and 76 that they would strike these but for the fact that each plunger head is notched at 97 to receive the tip 98 of the associated pawl. When the carton reaches its fully erected portion, at the bottom of the stroke of forming punch blocks 65 and 80, it clears the pawl tip, thereupon permitting the pawl to swing to its retracted position in which the tip 98 overlies the carton end wall as clearly shown in Fig. 20. Upon retraction of the forming punch blocks 65 and 80, the pawls engage the opposite ends of the carton to strip it from the punch blocks 65 and 80, whereupon the carton drops onto the cross conveyor 100 for lateral has vpulled the cover panel 33 toward the punch block 65 75 discharge from the machine.

envases While it is broadly immaterial' tothe presentinvention hdw the various parts are operated, a number ofthe actuating connections have been illustrated inthe drawings and are illustrative.

The motor-driven pulley 101 on shaft 102 operates a pinion 1193 meshing with a gear 104 on cam shaft`105. The cam 1de on this shaft acts on cam follower 107 to reciprocate the link 1nd which is pivoted/ to the rocker arm d of rock shaft 11o. The oscillation of rock shaft 11@ is communicated to the slide 67 which raises and lowers the forming die 65. The mechanism used comprises an arm 111 on rock shaft 110 and a link 112 which is pivoted between the ears 113 on the slide as shown both in Fig. l and Fig. 2.

Near its ends the cam shaft 1% carries cams 115 which engage follower rollers 116 to raise and lower the push rods 117 whereby motion is communicated to the sealing rams 75 and 76 for pressing the ends of the box against the flaps as above described, The same motion also operates the rams E92 and 93 for pressing the ends of the cover against its naps. As best shown in Fig. 1, the rod 117 has a guide 118 bifurcate'd to straddle the cam shaft 10d and to bind against axial displacement thereon by collars 119 and 126. Adjustably supported' on the push rod 117 by nut 121 is a spring-sealed collar 122 that supports a compression spring 123 bearing on a cross head 121i whereby the upper end of the push rod 117 is guided for movement when the spring 123 yields. The cross head is pivoted between a pair of arms 125 and 126 as best shown in Fig. l and Fig. 3. These arms are fulcrumed at 127. They operate a connecting r'od 12S which transmits motion to a cross head 129 having thrust bolts 13@ and 131 connected to the respective rams 75 and 76 for the box ends and and 92 for the cover ends, it being understood that the structures fully shown at the left of the machine as viewed in Fig. l and Fig. 3 are duplicated at the right.

The other cam 135 on the 'cam shaft 105 engages the cam follower 136 connected with a link 137 pivoted to arm 138 of rock shaft 139. Another arm 140 of rock shaft 139 is connected by link 141 with the arm 142 of rock shaft 143 on which the retractable die element 73 is mounted, and whereby this element is retracted after formation of the box, to prevent the descent of the box and the forming of the cover as above described. The feed rolls 49 and Stb and the glue rolls 46 are chain gear driven in synchronism with the camming operations.

l claim:

1. A method of erecting a blank integrally having walled tray and walled cover portions with wall corners to lap in the erected tray and "cover, such method cornprising the steps of glue-coating portions of the blank which will lap in the erected positions thereof, supporting tray wall areas of the blank while forcing the tray bottom area of the blanky through an erecting die to erect said wall areas in consequence of such support, drawing cover top and wall areas of the blank along the surface of the die in consequence of the step of forcing the tray bottom area of the blank through the die, and thereafter supporting cover wall areas of the balnk while forcing the cover top area through said die for the erection of the cover wall areas thus supported, and iinally pressing inwardly glued wall portions of the blank into engagement with blank areas interiorly lapped thereby in consequence of such erection, while supporting from within the tray and cover the areas against which such glued areas are pressed.

2. A method of erecting a box and cover in one operation from a blank integrally having box bottom and wall areas and box cover and wall areas, the said method comprising the lateral movement of the blank onto an erecting die, applying glue in the course of its advance to box and cover wall areas which will lap other portions of the blank in the erected box and cover, arresting movement of the blank when box portions thereof register with the erecting. die, moving a forming block against the box bottom area ofthe blank and through the die to carry said bottom. area with itV andV to effect erecting movement ofthe wall portions of the blank supported on the die, delaying the erection of blank wall portions which are to lap other portions of the` blank externally, whereby said other portions are erected in advance of external lapping portions, transmitting'motion from box wall portions of the blank to cover top and wall portions of the blank for drawing the latter along the die as the box wall portions are erected, and thereafter continuing the downward movement of the forming block and the box bottom and wall portions of the blank While advancing a second' forming block into engagement with the cover top portions of the blank and through said die to carry cover top portions of the blank through the die while erecting coverV wall portions of the blank supported upon the die, and. delaying the erection of cover wall portions which are to lap externally other portions ofthe blank whereby such other portions will iirst be erected, and nally pressing external wall portions of the bottom and cover into engagement with. other blank portions lapped thereby to complete the erection of the box and cover.

3-. A machine for erecting a blank in the manufacture of a box having an integral Yhinged cover, said machine comprising die means having spaced members comprising blank supporting surfaces and an intervening opening between said members, the 'said members having recesses extending from said opening vinto said members to leave said members with multiple edges, blank engaging means below said surfaces at said recesses and aligned withY certain said edges, and 'means *for advancing a forming block into and from saidV opening for engagement with portions of a blank provided with flaps having predetermined positions With respect to said edges and supported on said members, the position of one edge` with respect to another determining the relative 'time of erecting movement of flap portions of. the blank registering and non-registering with saided'ges'.

4. A machine for erecting a box t'ray and cover from a blank integrally providing tray bottom and cover top portions, and wall portions connected with said bottom and top portions, said machine comprising a die having openings through which the tray bottom and cover top portions are receivable, said die comprising wall portion supports, at least one of which is retractable, a pair of forming plungers normally retracted and mounted for successive advance through said die for forcing said tray bottom and cover top portions therethrough, means for retracting said retractable wall portion support portion after one of said forming plungers has advanced through the die and before the other of said forming plungers advances through the die.

5. The device of claim 4 in which one of said wall portion supports is provided with recessed portions so registering with wall portions of the blank as to eiect erection of certain wall portions in advance of other wall portions of the blank, the blank having internal wall portions requiring erection in advance of external wall portions of the blank which, in the erected position thereof, will externally lap the rst-erected internal wall portions.

6. A machine for erecting wall and wall ap portions of a blank for a box having an integrally connected cover and tray, each provided with wall portions and corner flaps, the cover comprising a top in hinged connection with wall portions of the tray, said machine including a feed table, means for advancing the blank thereover, means for applying adhesive in the course 0f such advance to wall portions of the tray and cover which are to lap ap portions aforesaid, a die constituting an extension of the feed table and having laterally spaced arms provided with notches opening into the intervening space and forming wall supporting portions in said arms, front .7 and rear forming bars spanning such space, a movable mount for the rear forming bar and upon which the rear forming bar is retractable, means for arresting the movementof the blank in a position in which the tray bottom registers with the space between said arms and between the front and rear forming bars, and a forming plunger movable through said space in registry with the tray bottom for carrying the tray bottom through the die and between said bars, and means for retracting the rear forming bar in -synchronism with the advance of said plunger.

7. The device of claim 6 inl which Wall supporting portions in -said die arms are spaced from the plunger paths and in registry with external wallportions of the blank, other `wall supporting portions extending into close proximity to the path of said plungers in registry with ap portions of the blank whereby to elect the erection of the ap portions in the interior of the box and cover more rapidly than the erection of external wall portions of the tray and cover.

8. The device of claim 7 in further combination with laterally reciprocable pressure means for pushing the external wall portions of the blank and cover toward said plungers and upon the intervening ap portions of the blank for effecting connection of the external wall portions with ap portions lapped thereby.

9. The device of claim 8 in which the die has a space behind the retractable rear forming bar with which the cover top registers on movement of the tray bottom portion of the blank through said die, and a second forming plunger movable beside the plunger rst mentioned through the last mentioned space in said die in registry with the cover top, portions of the die being engaged with wall and flap portions of the blank for the erection of the tray and cover walls as the tray -bottom and cover top respectively traverse the die.

10. The device of claim 9 including a slide upon which the first mentioned plunger is mounted for vertical reciprocation, a support for the second plunger in pivotal connection with the slide, means biasing the second mentioned plunger upwardly toward a normally retracted position, actuating connections for advancing the second mentioned plunger downwardly with the tirst mentioned plunger, and a stop in the path of said connections enf gaged by said connections in vthe downward movement of the slide and constituting a means for the actuation of said connections to advance the second mentioned plunger.

11. The device of claim 9 in which said dic arm notches are substantially equal in width to the width of the tray bottom, the end walls of the tray being in substantial registry with said notches for a portion of their height.

12. The device of claim 11 in which said arms have additional notches at the rear of the notches iirst mentioned, said portions for rapid flap erection intervening between said rst mentioned notches, and said additional notches.

13. A method of erecting a carton blank having panels which form side, bottom and end walls of a tray, and a cover hingedly connected to one of said side walls, said method comprising the steps of forcing the tray portions of the blank through an erecting die having forming members which fold the said side and end walls into angular relation to the bottom wall and concurrently draws the cover portion of the blank laterally over one of said forming members, and thereafter forcing the cover portion of the blank through an erecting die to which the cover has been -drawn in the step of forming the tray portion of the blank.

14, The method of claim 13 in which respective tray and cover portions of the carton blank are successively provided with internal support concurrently with the forcing of such portions through said dies.

References Cited in the file of this patent UNITED STATES PATENTS 

